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Plasma-electrolytic oxidation: A rapid single step post processing approach for additively manufactured biomedical
Victor M Villapún1, Luke N Carter1, Sophie C Cox1
1School of Chemical Engineering, University of Birmingham, Edgbaston B15 2TT, United Kingdom.
Biomaterials Advances
|January 18, 2025
Summary
Plasma-electrolytic oxidation (PEO) rapidly finishes laser-powder bed fusion (PBF-LB) implant surfaces, removing particles and enhancing bone growth. Further optimization is needed to manage inflammatory responses for improved medical applications.
Area of Science:
- Biomaterials Science
- Surface Engineering
- Additive Manufacturing
Background:
- Laser-powder bed fusion (PBF-LB) allows for customized skeletal implants with porous structures for bone ingrowth.
- PBF-LB surfaces exhibit roughness and adhered particles, hindering adoption and requiring extensive post-processing.
- Conventional finishing methods struggle with the complex geometries of PBF-LB parts.
Purpose of the Study:
- To investigate plasma-electrolytic oxidation (PEO) as a rapid, single-step surface finishing technique for PBF-LB implants.
- To assess PEO's effectiveness in addressing surface roughness and adhered particles on complex PBF-LB geometries.
- To evaluate the biocompatibility and osteogenic potential of PEO-treated PBF-LB surfaces.
Main Methods:
- PEO treatment was applied to as-printed and polished Ti-6Al-4V PBF-LB samples and porous lattices using a phosphate-based electrolyte.
- Surface characterization included optical profilometry, SEM-EDX, XRD, and XRF.
- Biocompatibility was assessed using MC3T3-E1 osteoblast cytotoxicity and mineralization assays over 21 days.
- Inflammatory response was evaluated by seeding RAW261 macrophages on PEO-treated surfaces and measuring iNOS and TNF-α expression.
Main Results:
- PEO treatment achieved complete surface coverage and chemical functionalization on Ti-6Al-4V PBF-LB samples within 20 minutes.
- PEO successfully coated clinically relevant BCC porous lattices, masking or removing adhered particles.
- No cytotoxicity was observed for osteoblasts, with significantly enhanced mineralization compared to controls.
- An enhanced pro-inflammatory response (iNOS, TNF-α) was noted in macrophages on PEO surfaces.
Conclusions:
- PEO is a rapid, geometrically unconstrained method for finishing PBF-LB surfaces, effectively addressing adhered particles.
- PEO-treated PBF-LB surfaces demonstrate promising biocompatibility and osteogenic potential for skeletal implants.
- Further optimization of PEO treatment is necessary to modulate the inflammatory response for optimal clinical application.
